Blind assembly fastener system

ABSTRACT

Disclosed are Systems and methods for coupling a first panel to a second panel using a fastening system. The fastening system includes a fastener, a doghouse structure, and a seal assembly. The fastener includes a head assembly coupled to a collar using the doghouse structure. The head assembly engages the doghouse structure positioned on the first panel and the collar passes through an opening in the second panel to retain the second panel relative to the first panel. The seal assembly includes a seal and a seal carrier that is coupled to the fastener via a frangible connection.

CROSS-REFERENCE

The present application claims the benefit under 35 U.S.C. § 119(e) ofU.S. Provisional Patent Application Ser. No. 63/022,612, filed May 11,2020, and entitled “Blind Assembly, Close-Panel, Doghouse InterfaceFastener System,” and U.S. Provisional Patent Application Ser. No.63/056,854, filed Jul. 27, 2020, and entitled “Readyset Seal,” thecontents of which are hereby incorporated by reference.

BACKGROUND

Automotive components require fastening techniques that are simple tomanufacture and assemble. Further, fastening techniques should above allbe reliable and efficient. A blind, close-panel assembly is a conditionwhere the fastening is focused between the panels being fastened to eachother (such as automotive panels or other components), while trying tokeep those same panels positioned very closely to each other.

Typical fastening solutions that allow this type of closely-positionedassembly include, magnets, adhesive tape, and mechanical fasteners. Forexample, a metal fastener can be used to make a blind connection betweenpanels. Traditionally, a simple metal fastener can be received within anopening (e.g., a window or aperture) formed in a primary panel andconfigured to engage a blade structure that extends from an undersurfaceof a secondary panel. Existing metal fasteners are deficient in that theabrasive nature of the metal fasteners often wears through the paint oranticorrosive coatings of the primary panel (e.g., the sheet metalframework of a vehicle), thereby promoting corrosion. In addition, metalfasteners have a tendency to buzz, squeak, and rattle, a conditiontypically referred to as “BSR.”

In an effort to mitigate BSR and to prevent corrosion, plastic fastenerscan be used as a replacement for metal fasteners. Such plasticfasteners, however, can increase the distance between panels andsometimes require moderately high insertion forces. In some examples,fasteners are fabricated using a combination of metal and plasticcomponents to mitigate abrasion and avoid BSR. Such fasteners, however,are typically larger and can be more difficult to manufacture. Further,while fasteners come in many sizes and levels of performance, manyfastener types cannot utilize a blade structure for blindpart-in-assembly (PIA) strategies.

It would therefore be highly desirable to have a fastener assembly withimproved assembly characteristics that provides reliable and securefastening, while allowing for the panels to be positioned very closelyto each other.

SUMMARY

The present disclosure relates generally to a fastening system to form ablind connection between the panels, such as automotive panels,substantially as illustrated by and described in connection with atleast one of the figures, as set forth more completely in the claims.

DRAWINGS

The foregoing and other objects, features, and advantages of thedevices, systems, and methods described herein will be apparent from thefollowing description of particular examples thereof, as illustrated inthe accompanying figures; where like or similar reference numbers referto like or similar structures. The figures are not necessarily to scale,emphasis instead being placed upon illustrating the principles of thedevices, systems, and methods described herein.

FIGS. 1 a through 1 d illustrate side views of example fastening systemsconfigured to form a blind connection between panels in accordance withaspects of this disclosure.

FIG. 2 a illustrates a perspective assembly view of the pass-throughdoghouse-based fastening system of FIG. 1 d in accordance with aspectsof this disclosure.

FIGS. 2 b and 2 c illustrate, respectively, partially assembled andassembled perspective views of the pass-through doghouse-based fasteningsystem of FIG. 2 a.

FIGS. 3 a through 3 d illustrate, respectively, a push pin fastener, apin and grommet (P&G) fastener, a box-prong fastener, and a specialtyfastener for use with a pass-through doghouse-based fastening system.

FIGS. 4 a and 4 b illustrate an example pass-through doghouse-basedfastening system configured with ribs in accordance with aspects of thisdisclosure.

FIGS. 5 a and 5 b illustrate an example pass-through doghouse-basedfastening system configured with ribs and wings in accordance withaspects of this disclosure.

FIGS. 6 a through 6 d illustrate an example pass-through doghouse-basedfastening system configured in accordance with another aspect of thisdisclosure.

FIG. 7 is a flowchart representative of an example a method of couplinga first panel to a second panel using the fastener of FIGS. 2 a through2 c.

FIGS. 8 a and 8 b illustrate, respectively, perspective and bottom planviews of a fastener with a seal assembly in accordance with an aspect ofthis disclosure.

FIG. 8 c illustrates a side view of the fastener of FIG. 8 a with theseal assembly assembled between panels.

FIGS. 9 a through 9 f illustrate perspective assembly views of thepass-through doghouse-based fastening system with a seal assembly duringassembly in accordance with an aspect of this disclosure.

FIG. 10 is a flowchart representative of an example a method of couplinga first panel to a second panel using the fastener with a seal assemblyof FIGS. 7 a through 7 c.

FIG. 11 is a flowchart representative of an example a method ofmanufacturing a fastening system with a fastener and a seal assembly.

DESCRIPTION

References to items in the singular should be understood to includeitems in the plural, and vice versa, unless explicitly stated otherwiseor clear from the text. Grammatical conjunctions are intended to expressany and all disjunctive and conjunctive combinations of conjoinedclauses, sentences, words, and the like, unless otherwise stated orclear from the context. Recitation of ranges of values herein are notintended to be limiting, referring instead individually to any and allvalues falling within and/or including the range, unless otherwiseindicated herein, and each separate value within such a range isincorporated into the specification as if it were individually recitedherein. In the following description, it is understood that terms suchas “first,” “second,” “top,” “bottom,” “side,” “front,” “back,” and thelike are words of convenience and are not to be construed as limitingterms. For example, while in some examples a first side is locatedadjacent or near a second side, the terms “first side” and “second side”do not imply any specific order in which the sides are ordered.

The terms “about,” “approximately,” “substantially,” or the like, whenaccompanying a numerical value, are to be construed as indicating adeviation as would be appreciated by one of ordinary skill in the art tooperate satisfactorily for an intended purpose. Ranges of values and/ornumeric values are provided herein as examples only, and do notconstitute a limitation on the scope of the disclosure. The use of anyand all examples, or exemplary language (“e.g.,” “such as,” or the like)provided herein, is intended merely to better illuminate the disclosedexamples and does not pose a limitation on the scope of the disclosure.The terms “e.g.,” and “for example” set off lists of one or morenon-limiting examples, instances, or illustrations. No language in thespecification should be construed as indicating any unclaimed element asessential to the practice of the disclosed examples.

The term “and/or” means any one or more of the items in the list joinedby “and/or.” As an example, “x and/or y” means any element of thethree-element set {(x), (y), (x, y)}. In other words, “x and/or y” means“one or both of x and y”. As another example, “x, y, and/or z” means anyelement of the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z),(x, y, z)}. In other words, “x, y, and/or z” means “one or more of x, y,and z.”

A fastener can be used to form a blind connection between a first paneland a second panel, such as automotive panels. In one example, afastening system for forming a sealed blind connection between a firstpanel and a second panel comprises: a fastener configured to retain thesecond panel via an opening formed in the second panel, wherein thefastener comprises a head assembly configured to engage a doghousestructure positioned on the first panel; and a seal assembly having aseal and a seal carrier, wherein the seal carrier is coupled to thefastener via a transitory connection. In some examples, the transitoryconnection is an adhesive, a frangible connection, and/or a mechanicalcoupling. In some examples, the fastener and the seal carrier arefabricated as a single component. The fastener and the seal carrier maybe fabricated via a plastic injection process. For example, thetransitory connection may be a flash-gate formed during the plasticinjection process. In some examples, the seal carrier is a rigid plasticstructure and the seal is over-molded onto the seal carrier. In someexamples, the seal carrier is configured to transition from an initialposition to a deployed position by breaking the transitory connection.The seal carrier may be configured to engage a feature of the fastenerto secure the seal carrier in the deployed position. The seal carriermay be configured to surround the doghouse structure when in thedeployed position. In some examples, the doghouse structure isconfigured to pass at least partially through the opening.

In another example, a method of forming a sealed blind connectionbetween a first panel and a second panel via a doghouse structure and afastener that has a head assembly and a seal assembly comprises: slidingthe head assembly across a surface of the first panel into a chamber ofthe doghouse structure; sliding the seal assembly from an initialposition to a deployed position, wherein the seal assembly comprises aseal and a seal carrier; and passing a portion of the fastener throughan opening formed on the second panel. In some examples, the initialposition is at or adjacent a collar of the fastener and the deployedposition is at or adjacent the head assembly. In some examples, the sealcarrier is coupled to the fastener in the initial position via atransitory connection. In some examples, the transitory connection is aflash-gate formed during a plastic injection process.

In yet another example, a method of manufacturing a fastening systemcomprises: forming a fastener via a plastic injection process, whereinthe fastener defines a head assembly, a neck, and a seal carrier,wherein the seal carrier is coupled to the neck by a transitoryconnection; and over-molding a seal on to the seal carrier. In someexamples, the transitory connection is a flash-gate formed during theplastic injection process. In some examples, the seal carrier is coupledto the neck via a collar. In some examples, the seal carrier isconfigured to separate from the neck via the transitory connection andto deploy to the head assembly.

FIGS. 1 a through 1 d illustrate side views of example fastening systems100 a, 100 b, 100 c, 100 d configured to form a blind connection betweena first panel 102 and a second panel 104. The first panel 102 and thesecond panel 104 may be, for example, automotive panels. Depending onthe application, the first panel 102 and the second panel 104 may befabricated from, for example, metal (or a metal alloy), synthetic orsemi-synthetic polymers (e.g., plastics, such as acrylonitrile butadienestyrene (ABS) and polyvinyl chloride (PVC), etc.), composite materials(e.g., fiber glass), or a combination thereof. In one example, the firstpanel 102 is an automotive secondary panel and the second panel 104 isan automotive primary panel. In the automotive industry, example firstpanels 102 include, without limitation, door trim panels, moldings, trimpieces, and other substrates (whether used as interior or exteriorsurfaces).

The first panel 102 may define an A-surface 102 a and a B-surface 102 b(illustrated as an undersurface). The A-surface 102 a, also called aclass A surface, is typically the surface that is visible after assemblyand, for that reason, is more aesthetically pleasing (e.g., textured,coated, or otherwise decorated) and typically free of attachment devicesand/or related features. Conversely, the B-surface 102 b, also called aclass B surface, is typically the surface that is not visible afterassembly and typically includes various attachment devices and/orrelated features.

The first panel 102 may be include, define, or otherwise be associatedwith attachment devices and/or related features, such as one or moretowers 108, doghouse structure 106, etc. Depending on the material type,the attachment devices and/or related features may be formed on theB-surface 102 b during molding or layup of the first panel 102, orattached after fabrication (e.g., using adhesive or mechanicalfasteners). After assembly, the second panel 104 is covered at leastpartially by the first panel 102. The second panel 104 may be, forexample, a structural component of a vehicle, such as doors, pillars(e.g., an A-pillar, B-pillar, C-pillar, etc.), dashboard components(e.g., a cross member, bracket, frame, etc.), seat frames, centerconsoles, fenders, sheet metal framework, or the like.

FIG. 1 a illustrates a clip-based fastening system 100 a configured tocouple the first panel 102 to the second panel 104. As illustrated, thefirst panel 102 may include one or more towers 108 that protrude fromthe B-surface 102 b. Each tower 108 (sometimes called a bezel orprotrusion) may be shaped as a blade or planar tab, for example. To formthe blind connection between the first panel 102 and the second panel104, the fastener 112 and the tower 108 are inserted into an opening 110formed in or on a surface of the second panel 104. In some examples, thefastener 112 may be pre-attached to either the tower 108 or the opening110 to define a part-in-assembly (PIA). The tower 108 of the first panel102 is inserted into a channel formed by the fastener 112 to, in effect,lock the fastener 112 in place within the opening 110, thus securing thefirst panel 102 and the second panel 104 to one another. The clip-basedfastening system 100 a eliminates rib setup variation and allows for arelatively close assembled distance (D₁) between the first and secondpanels 102, 104. A clip-based fastening system 100 a provides a blindPIA solution that positions the second panel 104 closely to the firstpanel 102 since the tower 108 can pass through the opening 110 in thesecond panel 104 to the B-side. Both the length of the fastener 112 andthe length of the tower 108 determine the protrusion distance (P₁) onthe B-side.

FIG. 1 b illustrates a doghouse-based fastening system 100 b configuredto couple the first panel 102 to the second panel 104. As illustrated,the first panel 102 may include one or more doghouse structures 106 thatprotrude from the B-surface 102 b. A doghouse structure 106 allows forthe first panel 102 to be used with a wide variety of fasteners 112,such as W-type fasteners, push pin fasteners, etc. For example, avariety of different fasteners 112 may be designed with a common headassembly that is sized and shaped to engage the doghouse structure 106,thus enabling interchangeability of the fasteners 112.

A fastener 112 is coupled to the doghouse structure 106 and configuredto pass at least partially through the opening 110 and engage the secondpanel 104. As illustrated, the doghouse structures 106 increases theassembled distance (D₂) between the first and second panels 102, 104.Thus, a doghouse-based fastening system 100 b can introduce a barrier toachieving close-panel, blind PIA fastening because the doghousestructure 106 occupies space between the first and second panels 102,104. As illustrated, the protrusion distance (P₂) through the B-side ofthe second panel 104 is dictated by the on the length of the fastener112. Therefore, a shorter fastener 112 may be employed to reduce theprotrusion distance (P₂).

FIG. 1 c illustrates a second doghouse-based fastening system 100 cconfigured to couple the first panel 102 to the second panel 104. Asexplained in connection with FIG. 1 b , the doghouse structure 106 canresult in a larger assembled distance (D₃). To reduce the assembleddistance, the second panel 104 may be shaped with a recessed panel 114to accommodate the doghouse structure 106. By using a recessed panel 114with a doghouse structure 106, the first and second panels 102, 104 canbe positioned much closer together to achieve a smaller assembleddistance (D₃). The recessed panel 114, however, must be large enough tohouse the doghouse structure 106. In some cases, a large recessed panel114 may negatively impact the overall assembly performance and/orappearance of the second panel 104. Further, the recessed panel 114increases the protrusion distance (P₃) through the B-side of the secondpanel 104, thus decreasing useable space on the B-side of the secondpanel 104.

FIG. 1 d illustrates a pass-through doghouse-based fastening system 100d configured to couple the first panel 102 to the second panel 104,while minimizing both the assembled distance (D₄) between the first andsecond panels 102, 104 and the protrusion distance (P₄) through theB-side of the second panel 104. The pass-through doghouse-basedfastening system 100 d uses a smaller doghouse structure 106 that isconfigured pass at least partially through the opening 110 in the secondpanel 104, thus achieving a small assembled distance (D₄) that iscomparable to the assembled distance (D₃) of FIG. 1 c , but withoutnecessitating the recessed panel 114.

FIGS. 2 a through 2 c illustrate an example pass-through doghouse-basedfastening system 100 d. Specifically, FIG. 2 a illustrates a perspectiveassembly view of the example pass-through doghouse-based fasteningsystem 100 d of FIG. 1 d , while FIGS. 2 b and 2 c illustrate,respectively, partially assembled and assembled perspective viewsthereof.

While a blind connection will be described primarily, it is to beunderstood, however, that the present fastening system may be adaptedfor use with structures other than the illustrated first and secondpanel 102, 104 that do not require the blind connection described.Accordingly, the present fastening system is not to be limited to onlyblind connections. Further, while only a single doghouse structure 106and a single opening 110 are illustrated in the examples, it should beappreciated that a given first panel 102 may include multiple doghousestructures 106 and the second panel 104 may include multiple openings110, depending on the number of fastener points to be used between thefirst and second panels 102, 104. In used, the head assembly 210 slidesinto the doghouse structure 106 as indicated by the first arrow 202 toform a PIA. Once in place, the fastener 112 may be inserted into theopening 110 of the second panel 104 as indicated by the second arrow204.

The fastener 112 generally comprises a head assembly 210, a neck 212, acollar 214, and one or more retention features 216. The head assembly210 is configured to engage a doghouse structure 106 of the first panel102. The neck 212, which couples the head assembly 210 to the collar214, is typically narrower than the head assembly 210 and the collar214. The collar 214 is configured to enter and engage (or otherwiseretain) the second panel 104 via, for example, the opening 110. As canbe appreciated, a portion of the neck 212 may also pass through theopening 110. The collar 214 may be secured within the opening 110 viaone or more retention features 216, which may be outwardly biased legscoupled to the collar 214. In some examples, the collar 214 may beomitted, in which case the retention features 216 may be coupleddirectly to the neck 212. The retention features 216 may include areturn arm 216 a resiliently connected to the collar 214 that deflectsas an end of the fastener 112 is inserted into an opening 110 of thesecond panel 104. A catch 216 b (e.g., a ledge, lip, etc.) may becoupled to a distal end of the return arm 216 a to engage the secondpanel 104 (e.g., at the perimeter of the opening 110). The retentionfeatures 216 are relatively rigid towards outward forces and as suchwill lock the collar 214 (or neck 212) into place within the secondpanel 104 once it has passed through the opening 110. Additionally, thefastener 112 may be configured to engage one or more features of thesecond panel 104.

The fastener 112 may be fabricated in various sizes depending on theapplication. The illustrated fastener 112 can be described as a “W-type”fastener because it generally resembles a “W” when viewed from a side,as best illustrated in FIGS. 1 b through 1 d . A W-type fastenerprovides lead-in features for finding the opening 110. While thefastener 112 is generally described and illustrated as a W-typefastener, as will be discussed in connection with FIGS. 3 a through 3 d, the fastener 112 may adopt other types of fasteners for use with thepass-through doghouse-based fastening system 100 d.

The opening 110 can be generally rectangular and define a size and shapethat is complementary to that of the fastener 112 such that the fastener112 can be inserted and retained therein. However, openings 110 of othershapes are contemplated. Therefore, the opening 110 may be rectangular,rounded rectangular (e.g., a stadium), circular (FIGS. 6 a to 6 d ),oval, or any other suitable shape.

As illustrated, the second panel 104 is sized and shaped to define theat the doghouse structure 106. The doghouse structure 106 acts as areceptacle for a head assembly 210 of the fastener 112. It is desirableto insert the head assembly 210 of the fasteners 112 into the chamber218 and retain it therein. As illustrated, the doghouse structure 106 iscomposed of a set of doghouse sidewalls 220 defining a chamber 218therebetween. The doghouse sidewalls 220 may include one or morefeatures shaped to increase engagement with the head assembly 210, suchas interference features 222. In some examples, the interferencefeatures 222 may exhibit a soft click as the fastener 112 is secured inthe chamber 218. The doghouse structure 106 provides a clear pathwayfrom one or more insertion openings to the chamber 218. In theillustrated example, the fastener 112 would be able to slide into thechamber 218 of the doghouse structure 106 from one of two insertionopenings. For example, the fastener 112 would be able to slide asillustrated by arrow 202 or in the opposite direction. It iscontemplated that the doghouse structure 106 may be molded duringmolding of the first panel 102; however, in some examples, they may befabricated separated and joined to one another (e.g., using adhesive,mechanical fasteners, etc.).

The doghouse structure 106 is contemplated to be modified in size andshape to suit individual applications. For example, while illustratedwith two opposing doghouse sidewalls 220, in some examples, the doghousestructure 106 may further include a doghouse endwall formed to bridgethe gap between the set of doghouse sidewalls 220, thereby walling offthree of the four sides of the chamber 218. In this example, thefastener 112 would only be able to slide into the chamber 218 of thedoghouse structure 106 from a single insertion opening, but would berestricted in movement at three sides.

As will become apparent, it is sometimes useful to assemble the firstpanel 102 and the second panel 104 by first inserting the fastener 112into the doghouse structure 106 of the first panel 102 (as indicated bythe first arrow 202) to form a PIA and then subsequently insertingfastener 112 of the PIA into an opening 110 of the second panel 104 (asindicated by the second arrow 204). In some examples, to assemble apass-through doghouse-based fastening system 100 d, the head assembly210 of the fastener 112 is slid laterally across a surface of the firstpanel 102 into the chamber 218 until fastener 112 stops (e.g., against awall) or is otherwise aligned between the doghouse sidewalls 220. Insome examples, the fastener 112 is held in place by interferencefeatures 222, which may exhibit a soft click as the fastener 112 issecured in the chamber 218. The fastener 112, now a PIA component withthe first panel 102 (FIG. 2 b ), may be shipped to a customer (e.g., anoriginal equipment manufacturer (OEM)). The OEM may then assemble thePIA component with a second panel (e.g., a vehicle panel) via all thefasteners 112 coupled thereto as illustrated in FIG. 2 c.

The doghouse structure 106 can make the head assembly 210 of thefastener 112 positionally located in a fixed manner or, if desired, toprovide the fastener 112 with some linear freedom (e.g., float) to movewithin the chamber 218. While a smaller doghouse can limit thepositional float of the head assembly 210 within the chamber 218,positional freedom requirements can be accomplished via the opening 110.Therefore, the pass-through doghouse-based fastening system 100 denables the doghouse structure 106 to directly interact with the opening110 to allow fasteners 112, such as W-type fasteners, to be part of adatum or locating solution.

The opening 110 may be sized to provide a desired amount of longitudinalmovement 208 a and/or lateral movement 208 b. In some examples, thepass-through doghouse-based fastening system 100 d may be configured toaccommodate 2-way assembly tolerance or float (e.g., for thermal growth)in the longitudinal direction (length) of the opening 110. The tolerancein the longitudinal direction may be, for example, about ±1 mm to ±5 mm,or about ±3 mm. In other examples, a 4-way version of the pass-throughdoghouse-based fastening system 100 d is contemplated with tolerance inthe lateral direction (width) as well as the longitudinal direction. Thetolerance in the longitudinal direction may be, for example, about 1 mmto ±3 mm, or about ±1 mm. In some examples, the lateral directiontolerance is less than the longitudinal direction tolerance, yielding anasymmetrical tolerance or float solution (e.g., the longitudinaldirection tolerance may be ±3 mm, while the lateral direction tolerancemay be ±1 mm). For example, as best illustrated in FIG. 2 c , theopening 110 may be lengthened along its longitudinal axis to definemovement gaps 206 that allow for longitudinal movement 208 a. The amountof lateral direction tolerance is dictated by the type of fastener 112used. For example, the width of the opening 110 cannot be wider than thewidth of the retention features 216 when the expanded since the catch216 b would need to engage a portion of the opening 110. In someexamples, the opening 110 may be sized to provide minimal longitudinalmovement 208 a and/or lateral movement 208 b, for example, with anassembly clearance of about ±0.25 mm.

Those of skill in the art would appreciate that the principles of thepass-through doghouse-based fastening system 100 d may be used withvarious types of fasteners 112, provided that the head assembly 210 isconfigured to engage the doghouse structure 106.

An end of the fastener 112 (e.g., the neck 212 and/or the collar 214)may be shaped as any desired type of fastener 112. FIGS. 3 a through 3 dillustrate, respectively, a push pin fastener 112 a, a pin and grommet(P&G) fastener 112 b, a box-prong fastener 112 c, and a specialtyfastener 112 d (e.g., a CenterLok™ fastener, which is available fromDeltar). As illustrated in FIG. 3 a , the push pin fastener 112 a(sometimes called trees, pine trees, Christmas trees, etc.) includes aplurality of barbs or teeth along its length. With reference to FIG. 3 b, the P&G fastener 112 b is a reusable two-piece fastener having a lowinsertion value. The P&G fastener 112 b may be a single positionfastener or a multi-position fastener. Each of the aforementionedfasteners can include a head assembly 210 is configured to engage thedoghouse structure 106 and used in lieu of a W-type fastener to fastencomponents and panels very closely to one other, while still using adoghouse structure 106. In some examples, as illustrated in FIG. 3 c ,the pass-through doghouse-based fastening system 100 d may comprises aseal 302 positioned between the first and second panels 102, 104. Forexample, a seal 302 may be used where it is desirable to mitigate dust,dirt, and/or moisture penetration through the opening 110. The seal 302may be embodied as a ring (e.g., an annulus) and fabricate from foammaterial, thermoplastic, rubber, etc. For example, as illustrated, aseal 302 can be configured to surround the doghouse structure 106between the first panel 102 and the second panel 104. In some examples,the pass-through doghouse-based fastening system 100 d may includeadditional features, such as ribs and wings.

FIGS. 4 a and 4 b illustrate example pass-through doghouse-basedfastening system 100 d configured with ribs 402. When assembled, theribs 402 reside between the first and second panels 102, 104 at aninterface between the doghouse structure 106 and the first panel 102.The ribs 402 serve as a buttress to increase the strength and support ofthe doghouse structure 106 (e.g., the doghouse sidewalls 220), whilealso controlling over-travel, where desired or required. Therefore, insome examples, the fastener 112 comprises one or more ribs 402configured to support the doghouse structure 106 and to controlover-travel.

FIGS. 5 a and 5 b illustrate example pass-through doghouse-basedfastening system 100 d configured with ribs 402 and wings 502. The wings502, which may be flexible, help control over-travel and mitigate BSR.When assembled, the ribs 402 and wings 502 reside between the first andsecond panels 102, 104. As illustrated, the wings 502 are coupled to thehead assembly 210 (e.g., near the retention features 216) and biased topush against the second panel 104 once assembled, effectively serving asa spring between the first and second panels 102, 104 to absorb movementbetween the first panel and the second panel.

While the doghouse structure 106 is illustrated as generallyrectangular, other shapes are contemplated, including otherquadrilaterals (e.g., square) and rounded shapes (e.g., circles andovals). For examples, FIGS. 6 a through 6 d illustrate an examplepass-through doghouse-based fastening system with a generally circulardoghouse structure 602 and a fastener 112 (again illustrated as a W-typefastener). As with the pass-through doghouse-based fastening systems ofFIGS. 2 a through 2 c , the doghouse structure 602 comprises a set ofdoghouse sidewalls 220; however, the doghouse sidewalls 220 are shapedto define a generally circular outer perimeter.

FIG. 7 is a flowchart representative of an example method 700 ofcoupling a first panel 102 to a second panel 104 using a pass-throughdoghouse-based fastening system having a doghouse structure 106 and afastener 112. The fastener 112 has a head assembly 210 and a neck 212.At step 702, the head assembly 210 slides across a surface of the firstpanel 102 into a chamber 218 of the doghouse structure 106. At step 704,at least a portion of the neck 212 and/or the collar 214 passes throughan opening 110 formed on the second panel 104. The neck 212 and/or thecollar 214 is configured to engage the second panel 104 via a retentionfeature 216. In some examples, the retention feature 216 includes areturn arm 216 a resiliently connected to a collar 214 that is coupledto a collar 214 and configured to deflect as the collar 214 is passedthrough the opening 110. As mentioned above, in some examples theretention features 216 are coupled to the neck 212 and a collar 214 isomitted. At step 706, passing at least a portion of the doghousestructure 106 through the opening 110.

As noted above, it is sometimes advantageous to seal the fastener,thereby preventing dirt, dust, and/or liquid from passing through thesecond panel 104 (e.g., via opening 110). If sealing is required ordesired, a seal may be added in one of multiple different ways. In someexamples, the seal may be pre-installed and/or integrally molded withthe fastener 112, which allows an over-molded seal to be integrallymolded to a fastener 112 and delivered to a customer as a PIA.

FIGS. 8 a through 8 c illustrate example pass-through doghouse-basedfastening systems 100 d configured with a seal assembly 800.Specifically, FIGS. 8 a and 8 b illustrate, respectively, perspectiveand bottom plan views of the fastener 112 with a seal assembly 800,while FIG. 8 c illustrates a side view of the fastener 112 with the sealassembly 800 assembled with the first and second panels 102, 104. Tobetter illustrate placement of the seal 802, the right-hand portion ofFIG. 8 c is illustrated as a cross-sectional view.

The seal assembly 800 generally comprises a seal 802 and a seal carrier804. The seal carrier 804 is connected to the fastener 112 by way of atransitory connection 806. In some examples, the fastener 112 is moldedas a single component with the seal carrier 804 connected to thefastener 112 by way of the transitory connection 806. In other examples,the fastener 112 and the seal carrier 804 are fabricated separately andconnected by way of the transitory connection 806. The seal carrier 804is configured to transition from an initial position to a deployedposition by breaking the transitory connection 806.

In one example, the seal carrier 804 is connected to the fastener 112 byway of a transitory connection 806 at the collar 214. In anotherexample, the seal carrier 804 is connected to the fastener 112 by way ofa transitory connection 806 at the neck 212. The transitory connection806 may be, for example, one or more of a frangible connection (e.g., athin, breakable features, such as tethers and flash-gates), a mechanicalcoupling (e.g., snaps, clips, etc.), an adhesive, or any other suitableconnection or coupling mechanism. As illustrated, the seal assembly 800is sized to surround the doghouse structure 106 when assembled betweenthe first and second panels 102, 104.

The seal 802 may be fabricated from a foam material, thermoplastic,rubber, etc. Example thermoplastics include, inter alia, polyethene(PE), polyvinyl chloride (PVC), etc. In some examples, the seal 802 isover-molded onto the seal carrier 804 to form the seal assembly 800.Therefore, in some examples, the wherein the seal carrier 804 is a rigidplastic structure and the seal 802 is over-molded onto the seal carrier804. The seal carrier 804 may be configured to engage and/or clip ontothe fastener 112 or doghouse structure 106. With reference to FIG. 8 a ,the fastener 112 may be provided with the seal 802 and the seal carrier804 positioned at a temporary location (e.g., at or near the collar 214or an end of the neck 212 opposite the head assembly 210). Once thefastener 112 is inserted into the doghouse structure 106, the seal 802and the seal carrier 804 may be slid over the fastener 112, breaking thetransitory connection 806, and toward the head assembly 210 (e.g.,toward the doghouse structure 106) as indicated by arrow 808. Once theseal assembly 800 is in place, the fastener 112 may be inserted throughthe opening 110 of the second panel 104, after which, the seal 802 andseal carrier 804 becomes sandwiched between the first and second panels102, 104 to seal the opening 110.

FIGS. 9 a through 9 f illustrate perspective assembly views of thepass-through doghouse-based fastening system with a seal assembly duringassembly in accordance with an aspect of this disclosure. FIG. 9 aillustrates a fastener 112 with a seal assembly 800 coupled thereto viaa transitory connection 806. As illustrated in FIGS. 9 b and 9 c , thehead assembly 210 of the fastener 112 is slid laterally across a surfaceof the first panel 102 into the chamber 218 until fastener 112 stops(e.g., against a wall) or is otherwise aligned between the doghousesidewalls 220. The first panel 102 and the second panel 104 may beplanar or curved. For example, the first panel 102 may be shaped todefine a first surface profile and the second panel 104 may shaped todefine a second surface profile that compliments or otherwisecorresponds to the first surface profile.

The seal assembly 800 is separated from its temporary initial positionon the fastener 112 using force. That force breaks or otherwiseseparates the transitory connection 806, making the seal assembly 800independent from the fastener 112. The force can be exerted by hand,through the use of a tool, by pressing the second panel 104 against theseal assembly 800, or through any other suitable manner.

With reference to FIG. 9 d , the seal assembly 800 is pushed onto thefastener 112 and into its final deployed position (e.g., around thedoghouse structure 106). In some examples, the fastener 112 or thedoghouse structure 106 may be designed to secure the seal assembly 800in its deployed position using, for example, clips, snaps, press fit,etc. The fastener 112, now a PIA component 900 with the first panel 102and the seal assembly 800, may be shipped to a customer (e.g., an OEM).The OEM may then assemble the PIA component 900 with a second panel(e.g., a vehicle panel) via all the fasteners 112 coupled thereto asillustrated in FIGS. 9 e and 9 f.

As can be appreciated, the assembly steps illustrated in FIGS. 9 athrough 9 f may be performed by one or more entities. In some examples,as best illustrated in FIGS. 9 a through 9 d , the seal assembly 800 caninstalled to the fastener 112 and doghouse structure 106 as a PIA (e.g.,by a Tier supplier) prior to shipment to the customer (e.g., an OEM). Insuch cases, the customer can then install the PIA to the second panel104 as best illustrated in FIGS. 9 e and 9 f . In some examples, theseal assembly 800 could be left in the position illustrated in FIG. 9 cand later installed by using force exerted during final assembly by thesecond panel 104 (e.g., effectively omitting the step illustrated inFIG. 9 d ). However, there exists is a risk of the seal assembly 800being knocked off the fastener 112 or the fastener 112 falling out ofthe doghouse structure 106 during transit to a customer. Therefore,installing the seal assembly 800 after the fastener 112 is placed in thedoghouse structure 106 as illustrated in FIG. 9 d prior to transit tothe next assembly step can be advantageous. This would also enable theoperator to confirm that the seal assembly 800 is seated properly.Further, with the seal assembly 800 protected by the fastener 112 andthe doghouse structure 106, it is much less likely to be dislodged priorto final assembly.

FIG. 10 is a flowchart representative of an example method 1000 offorming a sealed blind connection between a first panel 102 and a secondpanel 104 via a doghouse structure 106 and a fastener 112 that has ahead assembly 210 and a seal assembly 800. At step 1002, the headassembly 210 slides across a surface of the first panel 102 into achamber 218 of the doghouse structure 106. At step 1004, the sealassembly 800 slides or otherwise transitions from an initial position toa deployed position. The seal assembly 800 comprises a seal 802 and aseal carrier 804. In some examples, the initial position is at oradjacent the collar 214 of the fastener 112 and the deployed position isat or adjacent the head assembly 210. In some examples, the seal 802 isover-molded onto the seal carrier 804. The seal carrier 804 may becoupled to the fastener 112 in the initial position via a transitoryconnection 806. For example, the transitory connection 806 is aflash-gate formed during a plastic injection process. At step 1006, aportion of the fastener 112 e.g., the neck 212, the collar 214, orportion thereof passes through an opening 110 formed on the second panel104.

FIG. 11 is a flowchart representative of an example method 1100 ofmanufacturing a fastening system. At step 1102, a fastener 112 is formedvia a plastic injection process, wherein the fastener 112 defines a headassembly 210, a neck 212, and a seal carrier 804. The seal carrier 804is coupled to the neck 212 by a transitory connection 806. For example,the transitory connection 806 is a flash-gate formed during a plasticinjection process. In some examples, the seal carrier 804 is coupleddirectly to the neck 212 or coupled to the neck 212 via a collar 214.The seal carrier 804 is configured to separate from the neck 212 or thecollar 214 via the transitory connection 806 and to deploy to the headassembly 210. At step 1104, a seal 802 is over-molded on to the sealcarrier 804.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. For example, block and/orcomponents of disclosed examples may be combined, divided, re-arranged,and/or otherwise modified. Therefore, the present method and/or systemare not limited to the particular implementations disclosed. Instead,the present method and/or system will include all implementationsfalling within the scope of the appended claims, both literally andunder the doctrine of equivalents.

The invention claimed is:
 1. A fastening system for forming a sealedblind connection between a first panel and a second panel, the fasteningsystem comprising: a fastener configured to retain the second panel viaan opening formed in the second panel, wherein the fastener comprises ahead assembly configured to engage a doghouse structure positioned onthe first panel; and a seal assembly having a seal and a seal carrier,wherein the seal carrier is coupled to the fastener via a transitoryconnection, and wherein the seal carrier is configured to transitionfrom an initial position to a deployed position by breaking thetransitory connection such that the seal carrier surrounds at least aportion of the head assembly when in the deployed position.
 2. Thefastening system of claim 1, wherein the transitory connection is anadhesive.
 3. The fastening system of claim 1, wherein the transitoryconnection is a frangible connection.
 4. The fastening system of claim1, wherein the transitory connection is a mechanical coupling.
 5. Thefastening system of claim 1, wherein the fastener and the seal carrierare fabricated as a single component.
 6. The fastening system of claim5, wherein the fastener and the seal carrier are fabricated via aplastic injection process.
 7. The fastening system of claim 6, whereinthe transitory connection is a flash-gate formed during the plasticinjection process.
 8. The fastening system of claim 1, wherein the sealcarrier is a rigid plastic structure and the seal is over-molded ontothe seal carrier.
 9. The fastening system of claim 1, wherein the sealcarrier is configured to engage a feature of the fastener to secure theseal carrier in the deployed position.
 10. The fastening system of claim9, wherein the seal carrier is configured to surround at least a portionof the doghouse structure when in the deployed position.
 11. Thefastening system of claim 1, wherein the doghouse structure isconfigured to pass at least partially through the opening.
 12. Thefastening system of claim 1, wherein the seal comprises at least one ofa foam material, a thermoplastic material, or a rubber material.
 13. Thefastening system of claim 1, wherein the seal carrier is configured toengage a feature of the doghouse structure to secure the seal carrier inthe deployed position.
 14. A fastening system for forming a sealed blindconnection between a first panel and a second panel, the fasteningsystem comprising: a fastener configured to retain the second panel viaan opening formed in the second panel, wherein the fastener comprises ahead assembly configured to engage the first panel; and a seal assemblyhaving a seal carrier and a seal formed thereon, wherein the sealcarrier is configured to transition from an initial position to adeployed position by breaking a frangible connection between thefastener and the seal carrier, and wherein the seal carrier isconfigured to surround at least a portion of the head assembly when inthe deployed position.
 15. The fastening system of claim 14, wherein theseal assembly is generally rectangular.
 16. The fastening system ofclaim 14, wherein the seal carrier is a rigid plastic structure and theseal is over-molded onto the seal carrier.
 17. The fastening system ofclaim 14, wherein the head assembly is configured to engage the firstpanel via a doghouse structure positioned on the first panel.
 18. Afastening system for forming a sealed blind connection between a firstpanel and a second panel, the fastening system comprising: a doghousestructure positioned on the first panel; a fastener configured to retainthe second panel via an opening formed in the second panel, wherein thefastener comprises a head assembly configured to engage the doghousestructure; and a seal assembly having a seal carrier and a seal formedthereon, wherein the seal carrier is configured to transition from aninitial position to a deployed position by breaking a transitoryconnection between the fastener and the seal carrier, and wherein theseal carrier is configured to surround at least a portion of thedoghouse structure when in the deployed position.
 19. The fasteningsystem of claim 18, wherein the doghouse structure is generallyrectangular and configured to receive the head assembly laterally. 20.The fastening system of claim 18, wherein the seal carrier is configuredto engage a feature of the doghouse structure to secure the seal carrierin the deployed position.